Tetra Pak has launched the world’s first aseptic juice carton using a paper-based barrier, notably cutting reliance on fossil-based materials in a key step towards sustainable food packaging
The innovation, unveiled on December 10, 2025, was developed in partnership with Spanish beverage producer García Carrión and is being rolled out under its flagship Don Simón juice brand across multiple markets.
The new Tetra Brik® Aseptic 200 ml Slim Leaf carton is the first juice portion pack globally to replace the traditional aluminium foil barrier with a renewable, paper-based alternative, without compromising food safety or shelf life.
Made with up to 80 per cent paper, the carton combines the paper-based barrier with plant-based polymers, pushing renewable content to 92 per cent.
According to verification by the Carbon Trust, the packaging reduces carbon emissions by 43 per cent compared to conventional aseptic cartons that use aluminium foil and fossil-based polymers.
“This innovation supports our long-standing commitment to responsible production and environmental stewardship,” said José García Carrión, President of García Carrión.
He added: “It allows us to reduce environmental impact while continuing to deliver quality products to consumers.”
The launch represents a new industrial landmark for García Carrión’s 360° Sustainability Strategy, which earned it the Factories of the Future Award 2024 for excellence in sustainability and the circular economy.
Tetra Pak’s paper-based barrier replaces aluminium foil with a low-carbon, renewable alternative while maintaining protection against oxygen, light, moisture and bacteria, which are critical for food safety and long shelf life in aseptic packaging.
Importantly, the cartons can be collected, sorted and recycled at scale where recycling infrastructure exists, improving fibre recovery and enhancing efficiency in recycling systems.
“This launch marks a significant step in our journey toward fully renewable and recyclable food packaging,” said Tetra Pak Executive Vice President for Packaging Solutions, Tatiana Liceti.
She added: “It proves that sustainable innovation can scale across markets while preserving functionality and quality.”
The paper-based barrier is central to Tetra Pak’s broader ambition to develop the world’s most sustainable food package, one that is paper-based, made from responsibly sourced renewable or recycled materials, fully recyclable and with the lowest possible carbon footprint.
The technology builds on earlier success after Tetra Pak, in 2023, launched an aseptic beverage carton with a paper-based barrier in partnership with a dairy producer in Portugal.
The innovation went on to win the Resource Efficiency Award at the Sustainable Packaging News Awards 2024.
The launch is a clear shift toward scalable, paper-based solutions that align sustainability with commercial viability, coming as global food and beverage firms face growing pressure to decarbonise packaging and reduce plastic use.
